Patent application title: Position-Based Laser Triggering for Scanner

Abstract:

A method of directing a laser beam along a desired path on a workpiece and
at spaced intervals delivering a pulse of laser energy comprising the
steps of: using a position command stream and position feedback to
control the positioning of galvanometer scanned mirror or mirrors to
define the path a laser beam will travel to intersect the desired path on
the workpiece; and using position feedback alone to determine when a
pulse of laser energy is delivered to strike the workpiece at locations
such that are uniformly overlapped along the path notwithstanding
variations in galvanometer mirror velocity.

Claims:

1. A method of directing a laser beam along a desired path on a workpiece
and at spaced intervals delivering a pulse of laser energy comprising the
steps of:using a position command stream and position feedback to control
the positioning of galvanometer scanned mirror or mirrors to define the
path a laser beam will travel to intersect the desired path on the
workpiece; andusing position feedback alone to determine when a pulse of
laser energy is delivered to strike the workpiece at locations uniformly
overlapped along the path notwithstanding variations in galvanometer
mirror velocity.

2. A method of directing a laser beam along a desired path on a workpiece
and at spaced intervals delivering a pulse of laser energy comprising the
steps of:using a position command stream and mirror X-position and mirror
Y-position feedback to control the positioning of galvanometer scanned
mirror or mirrors to define the path a laser beam will travel to
intersect the desired path on the workpiece; andcontinuously summing the
squares of mirror X-position feedback and the mirror Y-position feedback
and comparing to a target value to determine when the next pulse of laser
energy is delivered to a location on the workpiece such that the
locations are uniformly overlapped along the path notwithstanding
variations in galvanometer mirror velocity.

3. A method according to claim 2, wherein the mirror X-position feedback
and mirror Y-position feedback are mapped to eliminate the pincushion
effect.

4. A method of directing a laser beam along a desired path on a workpiece
and at spaced intervals delivering a pulse of laser energy comprising the
steps of:using a position command stream and mirror position feedback to
control the positioning of galvanometer scanned mirror or mirrors and
stage position feedback to control the positioning of stage or stages on
which the workpiece is fixed which galvanometer(s) and stage(s) together
cause the laser beam to intersect the desired path on the workpiece,
andusing mirror and stage position feedback alone to determine when a
pulse of laser energy is delivered to a location on the workpiece such
that the locations are uniformly overlapped along the path
notwithstanding variations in galvanometer mirror velocity and/or stage
velocity.

5. A method of directing a laser beam along a desired weld path on a
workpiece and at spaced intervals delivering a pulse of laser energy
comprising the steps of:using a position command stream and mirror
X-position and mirror Y-position feedback to control the positioning of a
galvanometer scanned mirror or mirrors and stage X-position and
Y-position feedback to control the positioning of stage or stages on
which the workpiece is fixed which galvanometer(s) and stage(s) together
cause the laser beam to intersect the desired path on the workpiece;
andcontinuously summing the mirror X-position feedback and stage
X-position feedback and squaring the sum, and continuously summing the
mirror Y-position feedback and stage Y-position feedback and squaring the
sum, summing the squares and comparing the sum or change in sum to a
target value to determine when the next pulse of laser energy is
delivered to a location on the workpiece such that the locations are
uniformly overlapped along the path notwithstanding variations in
galvanometer mirror and/or stage velocity.

6. A method according to claim 5, wherein the mirror X-position and mirror
Y-position feedback are mapped to avoid the pincushion effect.

7. A method according to claim 6, wherein the stage position feedback or
mirror position feedback is scaled to match the resolutions of the
feedbacks.

8. A laser directing system comprising a triggerable laser, galvanometer
positioner with associated mirror or mirrors, rotary motors, and encoders
generating mirror X-position and mirror Y-position feedback signals,a
servo controller for directing a laser beam along a desired path on a
workpiece using a position command stream and mirror position feedback
signals to control the positioning of galvanometer mirror or mirrors to
define the path a laser beam will travel to intersect the desired path on
a workpiece; anda pulse controller using mirror position X-position and
mirror Y-position feedback signals alone to determine when a pulse of
laser energy is delivered to a location on the workpiece such that the
locations are uniformly overlapped along the weld path notwithstanding
variations in galvanometer mirror velocity.

9. The system according to claim 8, wherein the pulse controller comprises
means for continuously squaring the mirror X-position feedback signal and
the mirror Y-position feedback signal, summing the squares and comparing
the summed squares to a target value to determine when the next pulse of
laser energy is delivered to a location on the workpiece such that the
locations are uniformly overlapped along the weld path notwithstanding
variations in galvanometer mirror velocity.

10. The system according to claim 9, further comprising means for mapping
the mirror X-position feedback signal and mirror Y-position feedback
signal to eliminate the pincushion effect.

11. A laser directing system comprising a triggerable laser, a
galvanometer positioner with associated mirror or mirrors, rotary motors,
and encoders generating mirror X-position and mirror Y-position feedback
signals, workpiece stage or stages with associated linear motors, and
encoders generating stage X-position and stage Y-position feedback
signal, comprising:a servo controller comprising means for directing a
laser beam along a desired path on a workpiece using a position command
stream and position feedback to control the positioning of galvanometer
mirror or mirrors and stages to define the path a laser beam will travel
to intersect the desired path on the workpiece; anda pulse controller
using mirror and stage position feedback alone to determine when a pulse
of laser energy is delivered to a location on the workpiece such that the
locations are uniformly overlapped along the path notwithstanding
variations in galvanometer mirror velocity and/or stage velocity.

12. The system according to claim 11, wherein the pulse controller
comprises means for continuously summing the mirror X-position feedback
and the stage X-position feedback and squaring the sum, and continuously
summing the mirror Y-position feedback and stage Y-position feedback and
squaring the sum, summing the squares and comparing the sum or change in
sum to a target value to determine when the next pulse of laser energy is
delivered to form a weld bead on the workpiece such that weld beads are
uniformly overlapped along the weld path notwithstanding variations in
galvanometer mirror and/or stage velocity.

13. The system according to claim 11, wherein the mirror X-position and
mirror Y-position feedback are mapped to avoid the pincushion effect.

14. The system according to claim 11, wherein the stage position feedback
or mirror position feedback is scaled to match the resolutions of the
feedbacks.

15. A laser welding system comprising a triggerable laser, galvanometer
positioner with associated mirror or mirrors, rotary motors, and encoders
generating mirror X-position and mirror Y-position feedback signals;a
servo controller for directing a laser beam along a desired weld path on
a workpiece using a position command stream and mirror position feedback
signals to control the positioning of galvanometer mirror or mirrors to
define the path a laser beam will travel to intersect the desired weld
path on a workpiece; anda pulse controller using mirror position
X-position and mirror Y-position feedback signals alone to determine when
a pulse of laser energy is delivered to form a weld bead on the workpiece
such that weld beads are uniformly overlapped along the weld path
notwithstanding variations in galvanometer mirror velocity.

16. The laser welding system according to claim 15, wherein the pulse
controller comprises means for continuously squaring the mirror
X-position feedback signal and the mirror Y-position feedback signal,
summing the squares and comparing the summed squares to a target value to
determine when the next pulse of laser energy is delivered to form a weld
bead on the workpiece such that weld beads are uniformly overlapped along
the weld path notwithstanding variations in galvanometer mirror velocity.

17. The laser welding system according to claim 16, further comprising
means for mapping the mirror X-position feedback signal and mirror
Y-position feedback signal to eliminate the pincushion effect.

18. A laser welding system comprising a triggerable laser, a galvanometer
positioner with associated mirror or mirrors, rotary motors, and encoders
generating mirror X-position and mirror Y-position feedback signals,
workpiece stage or stages with associated linear motors, and encoders
generating stage X-position and stage Y-position feedback signal,
comprising:a servo controller comprising means for directing a laser beam
along a desired weld path on a workpiece using a position command stream
and position feedback to control the positioning of galvanometer mirror
or mirrors and stages to define the path a laser beam will travel to
intersect the desired weld path on the workpiece; anda pulse controller
using mirror and stage position feedback alone to determine when a pulse
of laser energy is delivered to form a weld bead on the workpiece such
that weld beads are uniformly overlapped along the weld path
notwithstanding variations in galvanometer mirror velocity and/or stage
velocity.

19. The laser welding system according to claim 18, wherein the pulse
controller comprises means for continuously summing the mirror X-position
feedback and the stage X-position feedback and squaring the sum, and
continuously summing the mirror Y-position feedback and stage Y-position
feedback and squaring the sum, summing the squares and comparing the sum
or change in sum to a target value to determine when the next pulse of
laser energy is delivered to form a weld bead on the workpiece such that
weld beads are uniformly overlapped along the weld path notwithstanding
variations in galvanometer mirror and/or stage velocity.

20. The laser welding system according to claim 18, wherein the mirror
X-position and mirror Y-position feedback are mapped to avoid the
pincushion effect.

21. The laser welding system according to claim 20, wherein the stage
position feedback or mirror position feedback is scaled to match the
resolutions of the feedbacks.

Description:

BACKGROUND OF THE INVENTION

[0001]1. Field of the Invention

[0002]This invention relates to precision laser welding, marking or
cutting. Pulses of laser energy are triggered on the change in position
of the galvo scanner used to direct the laser energy to the workpiece or
change in position of the galvo and the workpiece.

[0003]2. Description of Related Art

[0004]Apparatus for accurately positioning a laser beam on a workpiece
surface for various purposes are known in the art. For example, Overbeck
U.S. Pat. No. 4,532,402 entitled "Method and Apparatus for Positioning a
Focused Beam on an Integrated Circuit" discloses an X-Y positioning table
for moving the workpiece into the field of view of a galvanometer beam
positioning system. The galvanometer (typically referred to as a "galvo")
comprises two mirrors mounted for rotation. The mirrors are separately
controlled by drive assembles including scanning motors for directing a
laser beam over the workpiece. Control of the mirrors is coordinated with
the movement of the X-Y positioning table supporting the workpiece.
Interferometer position feedback from the X-Y positioning table is passed
to the galvanometer drive assembles making it unnecessary to move the X-Y
positioning table over the workpiece and await settling of the table at
the stopped position.

[0005]Precision laser welding wherein the overlapped weld beads are
applied along a weld seam is used in various applications, for example,
in production of implantable medical devices. Where a hermetically sealed
weld seam is required, overlapping weld beads are laid down along the
weld seam as disclosed, for example, in Papenfuss et al. U.S. Application
Publication No. 2006/0144827 entitled "Method and Apparatus for Laser
Welding Incorporating Galvanometer Delivery." This published patent
application teaches that the laser is pulsed at a fixed frequency, say 10
Hertz, while the galvanometer directs the beam along the weld path. This
represents the current state of the art known to applicant. The laser
pulses are timed by a constant frequency clock that is asynchronous to
the motion of the scanner mirrors and/or an X-Y positioning table
supporting the workpiece. The frequency of the laser pulses is based on
the laser spot size, desired spot overlap, and the programmed full speed
in one direction of the scan over the workpiece. This approach results in
varying spot overlap at the beginning and end of programmed motion
because the speed varies during the acceleration and deceleration of the
galvanometer mirrors. One attempt to overcome the problem is to change
the frequency of the laser pulses along the beam path. This reduces but
does not eliminate the overlap variation. This procedure can introduce
variability in pulse placement as the ideal point at which to modify the
pulse frequency does not coincide with the change in speed of the scan
over the workpiece.

SUMMARY OF THE INVENTION

[0006]Briefly, according to this invention, there is provided a method of
laser welding, marking or cutting. According to one embodiment of this
invention, there is provided a method of laser welding, marking or
cutting by directing a laser beam along a desired path on a workpiece and
at spaced intervals delivering a pulse of laser energy. The method
comprises a first step of using a position command stream and position
feedback to control the positioning of a galvanometer scanned mirror or
mirrors to define the path a laser beam will travel to intersect the
desired path on the workpiece. A second step comprises using position
feedback, without reference to the command stream, to determine when a
pulse of laser energy is delivered to form a weld bead on the workpiece
such that the laser pulses strike the workpiece at locations that are
uniformly overlapped along the path notwithstanding variations in
galvanometer mirror velocity.

[0007]A galvanometer positioning system, according to one embodiment of
this invention, uses the position command stream and the mirror
X-position and the mirror Y-position feedback to control the positioning
of a galvanometer mirror or mirrors to define the path a laser beam will
travel to intersect the desired path on the workpiece. According to this
embodiment, mirror X-position feedback and mirror Y-position feedback
signals are continuously squared and summed and the sum or the change in
the sum is compared to a target value to determine when the next pulse of
laser energy is delivered. In the case of welding, the weld beads are
thus uniformly overlapped along the weld path notwithstanding variations
in galvanometer mirror velocity.

[0008]According to another embodiment, a method comprises a first step of
using a position command stream and mirror position feedback to control
the positioning of a galvanometer scanned mirror or mirrors and stage
position feedback to control the positioning of a stage on which the
workpiece is fixed. The movements of the galvanometer and the stage
together cause the laser beam to intersect the desired path on the
workpiece. In a second step, mirror and stage position feedbacks are used
to determine when a pulse of laser energy is delivered to the workpiece
such that the laser pulses strike the workpiece at locations that are
uniformly overlapped along the weld path notwithstanding variations in
galvanometer mirror velocity and/or stage velocity.

[0009]A galvanometer positioning system, according to another embodiment
of this invention, uses a position command stream and mirror X-position
and mirror Y-position feedback to control the positioning of a
galvanometer mirror or mirrors. The command stream and the stage
X-position and the stage Y-position feedback control the positioning of a
stage or stages on which the workpiece is fixed. The mirror X-position
feedback and the stage X-position feedback are continuously summed and
squared, and the mirror Y-position feedback and stage Y-position feedback
are continuously summed and squared. The squares are then summed and the
sum or change in sum is compared to a target value to determine when the
next pulse of laser energy is delivered. In the case of welding, the weld
beads are thus uniformly overlapped along the weld path notwithstanding
variations in galvanometer mirror velocity and/or stage velocity.

[0010]According to a preferred practice, the mirror X-position and mirror
Y-position feedback are mapped with a two-dimensional error correction
function to avoid the pincushion effect. Also, the mirror feedback and
stage feedback are preferably scaled so as to match resolutions. In a
particular embodiment, the stage X-position and stage Y-position feedback
are scaled to match the resolution of the stage feedback to the
resolution of the galvanometer feedback.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]Further features and other objects and advantages will become
apparent from the following detailed description made with reference to
the drawings in which:

[0012]FIG. 1 schematically illustrates the arrangement of apparatus for
practice of one embodiment of this invention; and

[0013]FIG. 2 is a diagram illustrating the flow and processing of signals
in one embodiment of the systems and methods according to this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014]Generally, the present invention is directed to a system and method
for triggering a pulsed laser based on the substantially uniform vector
displacement along a path on a workpiece, for example, the weld path,
caused by rotation of the scanner mirrors. More specifically, the present
invention is a system and method that triggers a laser pulse for
application to a workpiece based on the real-time monitored vector
displacement caused by a pair of scanner mirrors that operate to scan the
pulsed laser beam in the direction of respective X and Y axes.

[0015]Referring to FIG. 1, the workpiece 10 to be welded is mounted on an
X-stage 12 which, in turn, is mounted on a Y-stage 14. Each stage is
controlled by a servo controller 25 and, for example, a linear motor (not
shown). The servo controller 25 compares a commanded position from a
command stream to position feedback signals usually generated by
encoders, for example, optical encoders, associated with the motors that
move the stages to place the workpiece in a position generally below an
X-galvo 16 and a Y-galvo 18. Each galvo is controlled by the servo
controller 25 which compares a commanded position from the command stream
with position feedback signals generated by encoders, for example,
optical encoders, usually associated with the rotating motors associated
with the galvos. It should be understood that other devices for
generating position feedback may be used in place of optical encoders.
The servo controller 25 compares the command stream with feedback signals
from the galvos to position the mirrors. A pulsed laser beam 22 is
deflected by a mirror associated with the X-galvo to a mirror associated
with the Y-galvo to the weld path on the workpiece 10. It should be
understood that the X-galvo and the Y-galvo can be combined into an X-Y
galvo having a single mirror that can rotate about two perpendicular
axes.

[0016]Pulse controller 24 processes X and Y galvo (mirror position)
feedback and X and Y stage feedback signals to determine when to trigger
the laser pulses as will be explained further with reference to FIG. 2

[0017]Real-time mirror positions in the respective X and Y axes are input
along with error correction functions that correct mirror positions due
to optical distortion. Positions of respective X and Y axis stages that
control movement of the workpiece are scaled into units consistent with
mirror displacement and then added to the corrected mirror displacement
calculation. The total displacement along the weld path in the respective
X and Y directions is then squared. These squared displacements are then
added together. When the added squared displacements along the respective
X and Y axes reach or surpass a target displacement, the pulsed laser is
triggered and the laser beam is applied to the workpiece.

[0018]Displacement of the beam on the workpiece is calculated based upon
the displacement of the scanner mirrors. Error mapping functions may be
utilized to modify the command positions of the scanner mirrors to
correct for optical distortion of the marking field ("pincushion effect")
while monitoring the real-time displacement of the scanner mirrors.
Additionally, motion of the workpiece along the X and Y axes of the X-
and Y-stages is accounted for by monitoring feedback from such motion. A
scale factor is applied to the feedback devices to match the resolution
of the feedback devices with the resolution of the scanner. Of course,
the inverse scale factor could be applied to the mirror position
feedback.

[0019]Referring now to FIG. 2, a laser triggering function is implemented
in a programmable logic device such as a field programmable gate array
(FPGA). The mirror X-position and the mirror Y-position feedback signals
30, 32 are fed to error mapping function 34 to compensate for the
pincushion effect. It should be understood that the mirror X-position or
mirror Y-position feedback signals are indicative of the rotation of the
mirror or mirrors that cause the reflected laser beam to move in the
X-direction or the Y-direction respectively. According to the present
invention, the mirror feedback signals are preferably corrected for the
pincushion effect. See, for example, U.S. Pat. No. 4,941,082 entitled
"Light Beam Positioning System" for error mapping functions applied to
position command signals for overcoming the pincushion effect. The
pincushion compensated signals 31 and 33 are passed to adders 46 and 59,
respectively. The stage X-position and Y-position feedback signals 38, 40
are fed to scaling functions 42, 44. The two X-position signals are added
at 46 and squared at 48. The two Y-position signals are added at 50 and
squared at 52. The squared signals are added at 60 and then compared at
54 to a squared target signal supplied from 56 and upon a match trigger a
laser pulse 62 which may have a programmable width at 58.

[0020]Having thus defined my invention in the detail and particularity
required by the Patent Laws, what is desired protected by Letters Patent
is set forth in the following claims.